Alpha ARES 440 Tec User guide

ARES 440 Tec
ARES 550 Tec
ARES 660 Tec
ARES 770 Tec
ARES 900 Tec
Floor standing, high output, modular
condensing boilers
Installation and Servicing
Instructions
Leave these instructions with the
Building Manager
ARES Tec

2
Alpha ARES Tec 440 - 900

3Alpha ARES Tec 440 - 900
is manual contains instructions for use by Gas Safe registered installers and/or maintenance
engineers, in compliance with Gas Safe and current British Standards.
e manufacturer will not be held liable in the case of damage to people, animals or property
due to the failure to observe the instructions supplied with the boiler.
1 General information...................................................................4
1.1 Symbols used in the manual........................................................4
1.2 Compliant use of the appliance...................................................4
1.3 Information to be provided to the user .....................................4
1.4 Safety warnings .............................................................................5
1.5 Regulations for installation..........................................................6
1.6 Installation.....................................................................................6
1.7 Water treatment ............................................................................7
1.8 General warnings..........................................................................8
2 Technical data and dimensions..................................................9
2.1 Technical data................................................................................9
2.2 View of main components.........................................................10
2.3 Dimensions..................................................................................11
2.4 Operating data / general data....................................................12
3 Instructions for installation.....................................................13
3.1 General recommendations ........................................................13
3.2 Packaging.....................................................................................14
3.3 Removing the boiler from the pallet and tting the feet.......15
3.4 Positioning the boiler.................................................................16
3.5 Connecting the boiler ................................................................17
3.6 Gas connection............................................................................18
3.7 System ow and return pipe connection.................................19
3.8 Additional safety, protection and control devices ..................20
3.9 Hydraulic separator....................................................................21
3.10 Hydraulic system lter ...............................................................21
3.11 Determining the primary circuit pump or boiler pump .......22
3.12 Valves............................................................................................22
3.13 Complete optional kits...............................................................23
3.14 Condensate drain........................................................................24
3.15 Connecting the ue ....................................................................25
3.16 Flue manifold connection..........................................................25
3.17 Electrical connections................................................................27
General recommendations........................................................27
230/240 V electrical supply connection...................................28
3.18 Wiring diagram for additional safety devices.........................28
3.19 Connection diagram ..................................................................29
Power supply, gas valve, safety group, On/O
pump, external sensor, ow switch...........................................29
Power supply, gas valve, safety group, modulating pump,
external sensor, ow switch.......................................................29
Safety group safety connection
(supplied with modulating pump). ..........................................30
On/O thermostat connection. ................................................30
Modulating room thermostats connection.............................31
Modulating zone manager connection....................................31
3.20 Practical connection diagram ...................................................32
3.21 Connections and management diagram..................................34
3.22 Examples of installation (functional diagram and
description of connections).......................................................36
3.23 System lling and draining........................................................41
3.24 Boiler frost protection................................................................41
3.25 Check and adjust the CO2values..............................................42
Nozzles - pressures. ....................................................................43
3.26 Emergency and safety operations ............................................45
3.27 First ignition................................................................................46
4 Inspections and maintenance ..................................................47
INDEX

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G 
Alpha ARES Tec 440 - 900
1.2 COMPLIANT USE OF THE APPLIANCE
e Alpha ARES Tec appliance was built to current standards in place.
Nevertheless, following improper use the safety and life of the user or other people may be exposed to danger, i.e. damage
to the appliance or other objects.
e appliance is designed for operation in hot water circulating heating systems.
Any other use is considered unsuitable.
e manufacturer will not be held liable for any damage resulting from improper use.
Any use in accordance with the envisioned purposes includes the strict observance of the instructions in this manual.
1.3 INFORMATION TO BE PROVIDED TO THE USER
e user must be instructed in the use and operation of the heating system, in particular:
• Hand these instructions to the user, as well as the other documents relative to the appliance contained in the packaging in an
envelope. e user must keep this documentation safe so that it is available for future consultation.
• Inform the user of the importance of ventilation and the ue/condensate system, highlighting how essential they are and how
it is strictly forbidden to change them.
• Inform the user on how to control the water pressure in the system as well as the operations required to restore it.
• Inform the user on how to correctly regulate the temperature, control units/thermostats and radiators in order to save energy.
• If the appliance is sold or transferred to another owner or if the owner moves, leaving the appliance behind, always ensure the
manual accompanies the appliance so that it may be consulted by the new owner and/or installer.
• It is recommended that servicing is carried out on an annual basis by a Gas Safe registered engineer.
e manufacturer will not be held liable in the case of damage to people, animals or property due to the failure to observe the instructions
contained in this manual.
1GENERAL
INFORMATION
1.1 SYMBOLS USED IN THIS MANUAL
When reading through this manual, pay special attention to the parts marked with these symbols:
DANGER!
Serious danger to
safety and life
ATTENTION!
Possibly dangerous situation
for the product and environment
NOTE!
Tips for the user

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G 
Alpha ARES Tec 440 - 900
1.4 SAFETY WARNINGS
ATTENTION!
e appliance must not be used by people with reduced physical, mental and sensorial capabilities, without experience and
knowledge. ese people must be duly instructed and supervised during manoeuvring operations.
ATTENTION!
Installation, adjustment and maintenance of the appliance must be carried out by a Gas Safe registered engineer.
DANGER!
Maintenance or repair work on the boiler must be carried out by a Gas Safe registered engineer, it is advisable to have an
annual maintenance contract.
Poor or irregular maintenance can compromise the operational safety of the appliance and cause damage to people, animals
and property for which the manufacturer will not be held liable.
Changes to parts connected to the appliance
Do not make changes to the following elements:
• To the boiler.
• To the gas, air, water and power supply lines.
• To the ue pipe, safety valve and condensate pipe.
• To the constructive elements that aect the operational safety of the appliance.
ATTENTION!
To tighten or loosen any threaded ttings, use suitable tools only.
Improper use and/or unsuitable tools can cause damage (i.e. water and gas leaks).
ATTENTION!
Instructions for appliances running on LPG gas
Make sure that the gas tank has been ventilated prior to installing the appliance.
For a thorough ventilation of the tank contact the liquid gas supplier and in any case authorised personnel, in accordance with
the law.
Ignition problems can arise if the tank is not thoroughly ventilated.
In this case contact the liquid gas tank supplier.
Smell of gas
In case of the smell of gas observe the following safety instructions:
• Do not smoke or strike matches.
• Do not turn electrical switches on or o.
• Do turn o the gas supply immediately.
• Do extinguish all sources of ignition.
• Do ventilate the room where the gas leak occurred.
• Do contact the National Gas Emergency Service on 0800 111 999.
Explosive and easily ammable substances
Do not use or deposit explosive or easily ammable materials (i.e. petrol, paints, paper, wood) in the room where the appliance
is installed.
ATTENTION!
e heating unit must be installed so as to avoid it from freezing and exposing the controls to temperatures below -15°C and
over +40°C.
e heating unit must be protected by:
• Insulating the water and condensate pipes.
• Adopting specic anti-freeze products in the water system.

6
G 
Alpha ARES Tec 440 - 900
1.5 REGULATIONS FOR INSTALLATION
e Alpha ARES Tec boiler is a gas category II2H3P heating unit.
e appliance must be installed in accordance with the instructions
contained in this manual.
Installation must be carried out by a Gas Safe registered engineer.
Gas Safe Register - 0800 408 5577 - www.gassaferegister.co.uk
It is necessary to observe the standards, regulations and requirements
for installation provided below, constituting a rough and non-exhaustive
list, in order to follow the changes in regulations. We would like to
underline that updating the list of standards is the responsibility of
the engineers authorised to carry out installation.
Also observe the standards regarding the heating control unit,
construction regulations and requirements on combustion heating in
the country of installation.
The appliance must be installed, commissioned and subject to
maintenance in accordance with all current regulations in force. is
also applies to the water system, the ue and condensate disposal
systems, the installation room and the electrical system.
Failure to observe the above regulations will void
the warranty.
ATTENTION!
If the new boiler has been tted in an old system
without it being thoroughly cleaned and ushed, do not
clean the system, as any sediments in the system may
ll the heat exchanger with residues aer replacement.
It is advisable to contact a company specialised in
water treatment.
If the ARES Tec boiler is being installed on a new system it is still
advisable to clean it thoroughly, using products that are suitable for the
entire system, and install a Y-strainer with two isolation valves on the
return pipe to the boiler, so that it can be cleaned as needed.
is lter will protect the boiler from sediments coming from the
heating system.
In both cases it is necessary to keep the head losses localised in the
primary circuit, for the correct sizing of the pump.
1.6 INSTALLATION
If the ARES Tec boiler is installed on existing systems, make sure that:
• e ue is suitable for condensing appliances, for the temperatures
of the combustion products, calculated and built in accordance with
regulations in force. at it is as straight as possible, water-tight
and insulated and does not have any obstructions or constrictions.
• e ue is equipped with an attachment to remove the condensation.
• e heating control unit is equipped with a pipe for the removal of
the condensation produced by the boiler.
• e electrical system is built in accordance with specic regulations
and by qualied technical personnel.
• e ow rate, head and direction of ow of the circulation pump
must be appropriate for the system.
• e gas supply line and any existing tanks are set up in accordance
with regulations in force.
• Ensure expansion vessels are correctly sized for the system to
accommodate the expansion of heated water.
• Ensure the system has been thoroughly cleaned and ushed.

7
G 
Alpha ARES Tec 440 - 900
1.7 WATER TREATMENT
Treating the supply water allows you to prevent problems and
maintain the functionality and eciency of the boiler over time.
e purpose of this treatment is to eliminate or signicantly reduce
problems that can be outlined as:
build-up
corrosion
sediments
biological growth (mould, fungus, algae, bacteria, etc.).
e chemical analysis of the water provides a lot of information on the
state and "health" of the system.
e pH level is a numerical indication of the acidity or alkalinity of
a solution.
e pH scale goes from 0 to 14, where 7 corresponds to neutral.
Values below 7 indicate acidity, values above 7 indicate alkalinity.
e ideal pH value in heating systems with aluminium boilers is
between 6.5 and 8, with a hardness of 15°f.
Water in a system with a pH value outside of this range considerably
accelerates the destruction of the protective oxide layer which forms
naturally inside the aluminium bodies, and would not occur naturally:
if the pH level is lower than 6 it contains acid, if it is above 8 the water is
alkaline, either due to an alkaline treatment (for example phosphates or
glycols operating as antifreeze) or in some cases the natural generation
of alkalis in the system.
Vice versa, if the pH value is between 6.5 and 8, the aluminium surfaces
in the body are passivated and protected from further corrosive attacks.
To minimise corrosion, it is essential to use a corrosion inhibitor.
In order for it to work eciently, however, the metal surfaces must
be clean.
When using inhibitors or cleaning agents they must be applied in
accordance with their manufacturers instructions. Only products
from Fernox and Sentinel are acceptable for use with AresTec boilers.
Further information can be obtained from Fernox (Tel: 01799
521133) or Sentinel (Tel: [phone])
The best inhibitors on the market also contain an aluminium
protection system that stabilises the pH levels of the ller water,
preventing sudden changes (buer eect).
It is advisable to systematically check (at least twice a year) the
pH value of the water in the system. In order to do so a chemical
laboratory analysis is not required, but a simple check using a
analysis "kit" contained in a carry case, easily available on the market.
THE PRESSURISATION UNIT, EXPANSION
VESSELS AND FILLING LOOP MUST BE SET
UP ON THE RETURN PIPE TO THE PRIMARY
CIRCUIT DOWNSTREAM OF THE PUMP.
Precautions are required to avoid the formation and localisation of
oxygen in the water of the system, for example plastic pipes used in
the under-oor heating systems must not be permeable to oxygen.
Make sure that any anti-freeze products are compatible with aluminium
and any other parts and materials in the system.
ATTENTION!
Any damage caused to the boiler, due to the formation
of build-up or corrosive water, will not be covered by
the warranty.
ATTENTION!
These appliances are designed and developed to
transfer heat to a heat carrying uid possessing the
characteristics described here, they are not suitable to
directly heat water intended for human consumption.

8
G 
Alpha ARES Tec 440 - 900
1.8 GENERAL WARNINGS
e instruction manual is an integral and essential part of the product
and must be kept safe by the individual in charge of the system.
Read the warnings contained in the manual carefully, as they provide
important instructions regarding installation, user and maintenance
safety.
Keep the manual safe for future use.
e appliance must be installed and maintained in accordance with
current regulations in force, adhering to the instructions of the
manufacturer, and by Gas Safe registered engineers, in accordance
to regulations in force.
Incorrect installation or poor maintenance can cause injury to persons
and animals and damage to property, for which the manufacturer is
not liable.
Before carrying out any servicing or maintenance operations on the
boiler, isolate it's electrical supply and close the appliance gas valve.
Do not obstruct the ventilation openings, ue terminal or condensate
pipe outlet.
In case of breakdown and/or poor operation of the appliance, switch it
o, and do not attempt in any way to repair it or intervene directly. Only
contact personnel that has been authorised in accordance with the law.
Any repairs to the products must be carried out by authorised Alpha
personnel only, using original spare parts only. Failure to observe
the above can jeopardise the safety of the appliance and will void the
warranty.
To guarantee the eciency of the appliance and its correct operation it
is essential for authorised personnel to carry out annual maintenance.
If the appliance is put out of use for downtime, any part that is
susceptible to posing a potential source of danger must be made safe.
Before re-commissioning an appliance that has been put out of use,
ush the domestic hot water system ensuring that the water has been
completely changed.
If the appliance is sold or transferred to another owner or if the
owner moves, leaving the appliance behind, always ensure the manual
accompanies the appliance so that it may be consulted by the new
owner and/or installer.
All appliances with options or kits (including electric) must only use
original spare parts.
e appliance must only be employed for its expressly foreseen use.
Any other use must be considered improper and therefore dangerous.

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T   
Alpha ARES Tec 440 - 900
2TECHNICAL DATA AND DIMENSIONS
2.1 TECHNICAL DATA
• A condensing boiler comprised of heating modules designed to
operate on their own or in a set.
• Can be installed inside or outside (IP X5D).
• Low water content.
• Quick response time to load changes.
• Single pipe ue that can be positioned on 3 sides.
• Reversible single gas supply pipe.
• Comprised of 4 or more heating modules (between 4 and 8),
aluminium/silicon/magnesium casting.
• Including low NOx premix modulating burners.
• None of the heating modules have hydraulic cut-o devices.
• Modulated output between 22 to 108 kW/module.
TEMPERATURE CONTROL DEVICES:
• Temperature sensor (each heating module).
• Limit ermostat (each heating module).
• Flow temperature sensor (manifold).
• Return temperature sensor (manifold).
• Approved safety thermostat (To be ordered and installed on safety
group, see Section 3.8).
• GCI global ow probe.
OTHER SAFETY DEVICES:
• See Section 3.8.
POP-UP control panel comprising:
• On/O switch (see Section 3.26).
• TGC (boiler thermoregulation/manager).
• GCI (internal cascade management board).
• Protection fuses.
• Any limit thermostats (only models over 350 kW).
• Fan air pressure switch.
• Condensate level sensor.
• Gas pressure switch.
• Flue pressure switch (anti-obstruction).
• Single temperature control sensors for the combined modules on
the ow and return manifolds.
• Integral insulation with non-allergenic synthetic wool.
• Modulating premix burner.
• Sound emissions at maximum output below 49 dBA.
• Operation during heating: determining the required input through
a control microprocessor, with preset comparison parameters
between requested temperature (or calculated by the outdoor
thermoregulation) and overall ow temperature.
• Logic of operation:
• Possibility of controlling the output of the single heating modules
for calibration and/or assistance with reserved access code.
• DHW production through priority temperature probe, to control
the storage tank temperature through a pump or three-way
diverter valve through the supplied TGC thermoregulator.
• Possibility of controlling the output of the single heating modules.
• Heat request control: temperature set point and modulation level.
• Monitoring the state of operation and temperatures.
• Alarm notication.
• Parameter setting.
• Control relay to switch on a pump at a xed speed.
• Analogue 0 to 10 V output to control a modulating pump.
• Emergency operation: this allows you to avoid system down time
due to an interruption in communication with the E8 control unit.
• e possibility of selecting the emergency temperature through
supplied 'Constant Set point' heating elements: 70°C, maximum
of 50% output.
• Alarm management.
• Alarm reset input.
• Alarm notication Relay.
• Easily removable integral panelling comprised of oven-painted steel
panels suitable for outdoor installation.
• Condensate collection tray with stainless steel ue trap and ue
chamber.
• Incorporated automatic air vent.
e request for heat can be generated by the TGC thermoregulation/
manager or alternatively by the GCI (internal cascade management
board).
The management logic envisions simultaneous operation of the
maximum number of heating modules, so as to always obtain the
maximum eciency. Since it guarantees the maximum exchange area
based on the delivered power. e modules are made to operate so as
to equally divide the operating time.
e hot water that is produced is circulated by the manifold pump
located on the return of the primary circuit to the ow of the hydraulic
separator. From here other pumps (see suggested system diagrams in
para. 3.21) circulate the ow to the various circuits. e return water
enters the hydraulic separator, to start the cycle again.

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T   
Alpha ARES Tec 440 - 900
To re-position the ue outlet to the le side of the
boiler, it is necessary to move cover 'A' with relative
cabling, level sensor and pressure switch pipe, to the
rear side of the boiler.
e rear cover (previously removed) must be put back
on the right side of the boiler.
2.2 VIEW OF MAIN COMPONENTS
Flue outlet RIGHT side (as supplied) - LEFT side and
REAR side (order rear ue gas outlet kit)
Flow RIGHT side (as supplied) - LEFT side
Return RIGHT side (as supplied) - LEFT side
Gas pipe RIGHT side (as supplied) - LEFT side
Fan
Gas Valve
Burner
Combustion Chamber
Heat Exchanger
Ignition Electrode
Control Panel
Trap
*Gas Pipe Connection
Condensation Collection
Tray/Flue Fitting
Frame
Min. depth 100 mm
Burner Cover
*Heating Flow
*Heating Return
Automatic Air Vent
Condensate Level Sensor
Limit Thermostat
Drain Point
* Flow, return and gas connections left side only

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T   
Alpha ARES Tec 440 - 900
2.3 DIMENSIONS
FRONT VIEW RIGHT SIDE VIEW
(As supplied, for le side attachments)
TOP VIEWLEFT SIDE VIEW
W1
287
W
62.5
24
Condensate drain
H
395
946
235
Condensate
drain
1267
534 327
R
F
G
122
==
ARES Tec 440 550 660 770 900
Dimensions Unit
Heating elements No. o 4 5 6 7 8
Height 'H' mm 1448 1448 1448 1448 1448
Width 'W' mm 1087 1355 1355 1623 1623
Width 'W1' mm 1039 1307 1307 1575 1575
Depth mm 946 946 946 946 946
Attachment sizes
Gas tting 'G' mm 80 80 80 80 80
System ow 'F' mm 100 100 100 100 100
System return 'R' mm 100 100 100 100 100
Flue tting mm 250 250 300 300 300
Condensate drain mm 40 40 40 40 40
Flue outlets:
Le side (supply condition)
Right side
Rear side

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T   
Alpha ARES Tec 440 - 900
2.4 PERFORMANCE DATA / GENERAL
DATA
(*) Room Temperature = 20°C
(**) See 'NOZZLES - PRESSURES' table, Section 3.24.
(***) e IP X5D degree of protection is obtained with the lid lowered.
ARES Tec 440 550 660 770 900
Boiler category II2H3P II2H3P II2H3P II2H3P II2H3P
Nominal heat input on L.V.C. Qn kW 432 540 648 756 864
Minimum heat input on L.C.V. Qmin kW 22 22 22 22 22
Nominal eective power (Tr 60 / Tf 80°C) Pn kW 424.35 530.44 636.53 742.62 849.05
Minimum eective power (Tr 60 / Tf 80°C) Pn min kW 20.57 20.57 20.57 20.57 20.57
Nominal eective power (Tr 30 / Tf 50°C) Pcond kW 445.0 557.8 670.1 783.2 900.3
Minimum eective power (Tr 30 / Tf 50°C) Pcond min kW 23.94 23.94 23.94 23.94 23.94
Eciency at nominal power (Tr 60 / Tf 80°C) % 98.23 98.23 98.23 98.23 98.27
Eciency at minimum power (Tr 60 / Tf 80°C) % 93.5 93.5 93.5 93.5 93.5
Eciency at nominal power (Tr 30 / Tf 50°C) % ~ 104 ~ 104 ~ 104 ~ 104 ~ 104
Eciency at minimum power (Tr 30 / Tf 50°C) % ~ 109 ~ 109 ~ 109 ~ 109 ~ 109
Eciency class according to directive 92/42 EEC -- 4 4 4 4 4
Combustion eciency at nominal load % 97.8 97.8 97.8 97.8 97.8
Combustion eciency at minimum load % 98.5 98.5 98.5 98.5 98.5
Losses from operating burner casing % 0.2 0.2 0.2 0.2 0.2
Losses from burner casing when switched o -- 0.1 0.1 0.1 0.1 0.1
Flue losses with burner on % 2.58 2.53 2.51 2.58 2.58
Flue temperature at net of Tf-Ta (max) °C 46.7 46.7 46.7 46.7 45.8
Maximum ue ow rate (max) kg/h 693 866 1040 1213 1386
Air excess % 24.25 24.25 24.25 24.25 24.25
(**) CO2 (min/max) % - - - - -
NOX (weighted value according to EN 15420)
mg/kWh 49 49 49 49 49
NOXclass -- 5 5 5 5 5
Water ow rate at nominal power (∆T 20°C) l/h 18247 22809 27371 31933 36509
Minimum pressure of heating circuit bar 0.5 0.5 0.5 0.5 0.5
Maximum pressure of heating circuit bar 6 6 6 6 6
Water content l 67 80 94 108 122
NG consumption G20 (supp.press. 20 mbar) at Qn m3/h 45.68 57.10 68.52 79.94 91.36
NG gas consumption G20 (supp.press. 20 mbar) at Qmin m3/h 2.33 2.33 2.33 2.33 2.33
LPG consumption (supp.press. 37 to 50 mbar) at Qn kg/h 33.53 41.92 50.30 58.68 67.07
LPG consumption (supp.press. 37 to 50 mbar) at Qmin kg/h 1.71 1.71 1.71 1.71 1.71
Maximum pressure available at ue base Pa 100 100 100 100 100
Max condensate production kg/h 73.4 91.7 110 128.4 146.7
Emissions
CO with 0% of O2in the exhaust ppm <95 <95 <95 <95 <95
NOxwith 0% of O2in the exhaust ppm <30 <30 <30 <30 <30
Sound dBA <49 <49 <49 <49 <49
Electrical data
Power supply voltage / Frequency V/Hz 230/50 230/50 230/50 230/50 230/50
Supply fuse A (F) 4 4 4 4 4
Maximum power W 626 783 940 1096 1252
(***) Degree of protection IP X5D X5D X5D X5D X5D
Consumption in stand-by W 20 20 20 20 20

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I   
Alpha ARES Tec 440 - 900
3INSTRUCTIONS FOR INSTALLATION
3.1 GENERAL RECOMMENDATIONS
ATTENTION!
is boiler must only be employed for its intended
use. Any other use must be considered improper and
therefore dangerous.
is boiler is used to heat water to below boiling
temperature at atmospheric pressure.
ATTENTION!
These appliances are designed exclusively for
installation inside suitable boiler rooms.
Before connecting the boiler, have professionally
qualied personnel:
a) Flush and clean all of the pipes in the system to
remove any residues or sediment that could stop
the boiler from running eciently.
b) Make sure the boiler is set up to operate with the
correct type of fuel. e type of fuel is stated on the
packaging and technical data plate.
c) Make sure that the ue has been designed correctly
to completely remove the products of combustion.
d) Ensure that the ue has an adequate draught, that it
is not blocked, and that there are no ues from other
appliances connected to it.
Only once these checks have been carried out can the
boiler be connected to the ue.
ATTENTION!
In atmospheres with aggressive vapour or dust, the
appliance must operate independently of the air in
the room in which it is installed!
ATTENTION!
The appliance must be installed by Gas Safe
Registered engineers.
ATTENTION!
Ensure there is adequate clearance to install the
appliance and provide sufficient clearance for
maintenance.
e boiler must be connected to a heating system
compatible with its specications and output.

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Alpha ARES Tec 440 - 900
C
BA
3.2 PACKAGING
e ARES Tec boiler is supplied assembled in a box on a pallet.
Once the two straps have been removed, li the box
o from the top and make sure the contents are intact.
Packaging materials (cardboard box, straps, plastic bags,
etc.) constitute a potential hazard and must be kept
out of the reach of children.
Alpha will not be held liable in case of damage caused
to people, animals or property due to failure to observe
the above.
Contents of pack.
On the le side of the boiler:
• e ue exhaust manifold.
• A cardboard box containing:
• Gasket between pan and terminal.
• Collar gasket (Ø 250) Ø 300.
• Two bends + 1 x tee + plastic cap for condensate drain.
• Screws required to secure the ue terminal.
• Sensors: external, ow, storage tank.
• Flue inspection cap.
• Kit of resistances.
• Plate and cable clamp for power output.
• A cardboard box containing:
• Flanges.
Inside the rear side of the casing:
• Condensate drain trap pipes (1 m).
Above the boiler cover:
• A plastic bag containing:
• Installation and servicing instructions.
• System manager instructions handbook.
• TGC control unit user handbook.
• Warranty certicate.
• Hydraulic test certicate.
• Control unit handbook.
• Spare parts list.
• Support pins (for burner service mode).
Model A (mm) B (mm) C (mm) Gross
Weight (kg)
440
550
660
770
900
1263
1531
1531
1799
1799
1120
1120
1120
1120
1120
1515
1515
1515
1515
1515
585
643
707
806
858
Position of contents

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Alpha ARES Tec 440 - 900
1
Max.admitted boilers
stacked
Donot turn upside down Donot expose to rain Fragile Donot expose to sunlight Donot store at
temperature:
lowerthan - 5 ° C / 23 °F
morethan 50 °C / 122 °F
Tma x
50°C/122° F
Tmin
-5°C/23°F
2
Max.admitted boilers
stacked
Donot turn upside down Donotexpose to rain Fragile Donot expose to sunlight Donotstoreat
temperature:
lowerthan - 5 ° C / 23 °F
morethan 50 °C / 122 °F
Tmax
50°C/122°F
Tmin
-5°C/23°F
3
Max.admittedboilers
stacked
Donotturn upside dow n Donot expose to rain Fragile Donotexpose to sunlight Donotstore at
temperature:
lowerthan- 5 ° C / 23 °F
morethan50 °C / 122 °F
Tmax
50°C/122°F
Tmin
-5°C/23°F
4
3.3 UNLOAD THE BOILER AND REMOVE
THE PACKAGING
ATTENTION!
Handle using forkli or hoist and sling.
ATTENTION!
Sling slotting points for liing. e slings must be
assembled on the load bearing crossbeams.
To remove the boiler from the pallet it is necessary to use a hoist or
crane, to avoid damaging it.
• Remove the casings and harness it using slings, being careful to
pass the slings through the load bearing crossbeams of the frame
as shown in the following diagrams and photographs.
• Tie the slings to the jib. Perform these operations with caution.

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Alpha ARES Tec 440 - 900
Observe the minimum clearances required to perform
normal maintenance and cleaning operations.
3.4 POSITIONING THE BOILER
Special attention must be paid to British Standards and Gas Safety
Regulations regarding commercial boilers, minimum clearances listed
below must be observed.
e installation must comply with the requirements contained in the
most recent standards regarding heating system installation and hot
water production, i.e. gas red hot water boilers of rated input between
70 kW and 1.8 MW, referring to BS 6644 and IGE/UP/10.
e boiler can be placed on a suitable sturdy at platform no smaller
than the boiler measurements and with a minimum height of at least
100 mm so that the trap for condensate drainage can be installed.
Alternatively, a sump can be built next to the boiler, at a depth of 100
mm so that the trap can be placed in it (Section. 3.14).
When installation is complete the boiler should be perfectly horizontal
rm and stable (to reduce vibrations and noise).
A > 400 mm
B > 400 mm
C = 100 mm
D = 500 mm Trap
AB
D
C
E
E = 600 mm

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Alpha ARES Tec 440 - 900
3.5 CONNECTING THE BOILER
e ARES Tec boiler is despatched with the ow and
return manifolds, gas and ue connections positioned
on the le hand side of the boiler.
To attach the ue manifold use the screws and gaskets supplied in the
accessory kit box and a 10 mm socket.
e ue manifold is set up on the LEFT SIDE. It is also possible to move
the outlet to the RIGHT or REAR SIDE.
Looking down on boiler
Alternative
ue positions
System ow
and return
Gas
connection
Flue position
as supplied
'O' rings and gaskets.
'O' rings - Fitted in the rst and last element of the ow manifold 18
mm internal dia. (A), 27 mm internal dia. (B).
Gaskets - Fitted on all of the other elements (C).
A
C
B
A

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Alpha ARES Tec 440 - 900
3.6 GAS CONNECTION
e gas supply pipe must be connected to the boiler using a 3" ange
as indicated in Section 2.3.
e supply pipe must have a section equal to or larger than the one used
in the boiler and must provide the correct gas pressure.
It is advisable to adhere to the standard specications and requirements
in force, installing a gas supply isolation valve, gas lter, anti-vibration
joint, etc.
e gas supply pipe to the boiler must be tested for tightness and purged
referring to IGE/UP/1 and 1A.
DANGER!
The gas connection must be installed and
commissioned by an authorised Gas Safe registered
engineer who must observe and adhere to the Gas
Safety (Installation and Use) regulations 1998 and
the local requirements of the gas supply company,
as incorrect installation can cause damage to people,
animals and property, for which the manufacturer
will not be held liable.
EXAMPLE OF GAS SUPPLY SYSTEM
Before installation it is advisable to clean the inside
of the gas supply pipe thoroughly, in order to remove
any residues that could stop the boiler from operating
smoothly.
If you notice the smell of gas:
a) Close the gas valves.
b) Do not operate electrical switches, the telephone or
any other object that can generate sparks.
c) Immediately open doors and windows to create an
air current that puries the room.
d) Seek the assistance of professionally qualified
personnel.
In order to detect any gas leaks it is advisable to install
a surveillance and protection system composed of a gas
leak detector combined with a cut-o safety shut-o
on the gas supply pipe.
43
INSIDE BOILER
PLANT ROOM
OUTSIDE BOILER
PLANT ROOM
1 - Isolation valve
2 - Gas solenoid valve
3 - Appliance isolation valve
4 - Test and purge point
21

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Alpha ARES Tec 440 - 900
3.7 SYSTEM FLOW AND RETURN PIPE
CONNECTION
e heating ow and return must be connected to the boiler by the 4"
ow (F) and return (R) connections as indicated in Section. 2.3 and
shown in the diagram below.
For heating circuit pipe sizing it is necessary to take into account
the head losses induced by the components of the system and its
conguration.
e layout of the pipes must be set up taking every necessary precaution
to avoid air pockets and to facilitate continuous removal of air from
the system.
ATTENTION!
Before connecting the boiler to the system thoroughly
clean the pipes terminating at the boiler with a
suitable product, in compliance with standards, in
order to eliminate metal residues from machining
and welding, any oil and grease that could aect its
operation.
Do not use solvents to wash the system, as they might
damage the system and/or its components.
Failure to observe the instructions in this manual
can cause damage to people, animals and property,
for which the manufacturer will not be held liable.
Make sure the pipes in the system are not used as
earthing connections for the electrical or telephone
system. ey are not suitable for this purpose. Serious
damage to pipes, boiler and radiators could occur in a
short amount of time.
ATTENTION!
DONOTINSTALLISOLATION VALVESBETWEEN
THE BOILER AND THE SAFETY DEVICES.
G
F
R
GCI

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Alpha ARES Tec 440 - 900
3.8 ADDITIONAL SAFETY, PROTECTION
AND CONTROL DEVICES
Regulations regarding additional safety devices: closely consult the
legislative regulations and safety provisions in force in the country of
installation of the appliance.
Use the gas safety and cut-o valves suitable for application and
compliant with provisions in force.
e boiler is not supplied with an expansion vessel for the system. It
is mandatory to install a closed expansion vessel to guarantee correct
boiler operation. e expansion vessel must be compliant with standard
requirements in force. e size of the expansion vessel depends on
the data for the central heating system. Install a vessel with a capacity,
determined by an authorised designer.
Safety devices.
1 Gas cut-o valve: this has the function of directly cutting-o the
gas supply if the limit value of the water temperature is reached. e
detection element must be installed as close as possible to the boiler
ow pipe at a distance of < 500 mm, and must not have an isolation
valve installed between it and the boiler. Not supplied by Alpha.
2 Safety valve: this has the function of releasing the uid contained
in the boiler into the atmosphere when it reaches the maximum
operating temperature for any reason. Not supplied by Alpha.
2a Visible tundish. Not supplied by Alpha.
Install a discharge pipe from the safety valve via a tundish, to a drain
that can be visually controlled. e pipe material must be of copper or
steel and be at least the same diameter of the safety valve throughout
its length.
Install a safety valve, on the ow pipe, sized for boiler capacity, within
0.5 m of the boiler, and in compliance with regulations in force.
ATTENTION!
Do not install any type of isolation device between
the boiler and the safety valve.
Attention!
e manufacturer will not be held liable in the case of
failure to observe this precaution, where any work on
the safety valve may cause damage to people, animals
and property.
Protection devices.
10 Safety thermostat: this is designed to shut down the boiler if the
safety thermostat installed on the boiler fails to operate correctly.
It must have an IMMOVABLE calibration of < 100°C.
15 Minimum pressure switch: this is designed to shut down the boiler
if the minimum operating pressure drops (can be calibrated between
0.5 - 1.7 bar). It must be manually reset.
16 Extra socket 1".
18 Safety pressure switch: this is designed to shut down the boiler
if the maximum operating pressure is reached (can be calibrated
between 1 - 5 bar).
Control devices.
13 (Pressure gauge - not supplied by Alpha) with (12) damper pipe
and (11) pressure gauge valve: it indicates the current pressure in
the boiler, it must be graduated in 'bar', its full scale must match the
maximum operating pressure and be equipped with a three-way
valve with an attachment for the control pressure gauge.
14 ermometer: this indicates the current temperature of the water
contained in the boiler, it must be graduated in centigrade with a
full scale of no more than 120°C.
17 Spare socket: approved for the inclusion of control devices.
19 1¼" stub pipes: for the inclusion of safety valves (Not supplied).
20 Flow switch: this is designed to shut down the boiler in case of low
ow inside the primary circuit.
3 Approved expansion vessel: this absorbs the increase in volume
of water in the system following an increase in temperature. Not
supplied by Alpha.
8 Y strainer.
7 Modulating pump (Not included in the kit).
5 Hydraulic separator (Not included in the kit).
4 Automatic air vent. Not supplied by Alpha.
6 Drain cock. Not supplied by Alpha.